Garment assembly

ABSTRACT

A garment comprises an outer shell ( 4 ) and an inner liner ( 2 ). The inner liner is a liquid-water-resistant and water-vapour-permeable material (particularly coated expanded polytetrafluoroethylene membrane) which has a discontinuous pattern of abrasion-resisting polymeric material on the side which faces the outer shell. The pattern may be a pattern of dots ( 26 ) of abrasion-resisting polymer. The outer shell may be removable from the inner liner.

[0001] The present invention relates to a garment assembly comprising anouter shell and an inner liner; and to a liner for use in the assembly.In particular, the invention relates to a garment assembly wherein theinner liner is water-resistant and water-vapour-permeable and the outershell is fixed or replaceable.

[0002] Garments comprising an inner liner which is water-resistant andwater-vapour-permeable and which have a replaceable outer shell areknown. The replaceable outer shell is generally attached to the innerliner in a removable manner e.g. by zips or press-studs, and gives thewearer the flexibility to choose the colour or fabric of the outer shellindependently of the nature of the inner liner (which imparts thenecessary water-resistance and water-vapour-permeability).Water-resistance means that under normal conditions of wear, the garmentis impervious to penetration by liquid water. Water-vapour-permeabilityis the ability for moisture exuded from the body of the wearer to passthrough the inner liner so as to prevent build up of moisture inside thegarment, making it uncomfortable to wear.

[0003] A known construction of such a garment involves an inner linerformed of an expanded polytetrafluoroethylene (ePTFE) membrane having awater-vapour-permeable polymeric coating on an inner surface thereoffacing the body of the wearer. In order to protect the water-resistantwater-vapour-permeable membrane, a knitted material is normallylaminated to an inner side of the mebrane and another knitted layer islaminated to the outer side of the membrane to protect against abrasionwith the outer shell of the garment. However, a problem with this knownconstruction is that under rainy conditions, water penetrates the outershell and wets the outer facing knitted layer of the inner liner. Thisknitted layer becomes saturated with water and gives the garment aclammy feel to the wearer and also adds extra weight. This derives fromthe water absorbancy and retention properties of the knitted materialsconventionally used on the outer side of the liner.

[0004] A further problem with this known constructions is that it issometimes difficult to seam-seal the seams of the inner liner to providethe required water-resistance to the liner as a whole, due to thepresence of the outward facing knitted layer. As is known,water-resistant water-vapour-permeable garments of this type aregenerally seam-sealed to provide water-tightness by applying a tape overseams in the garment to prevent water ingress through the seams.

[0005] It is an object of the present invention to mitigate thesedisadvantages.

[0006] Broadly speaking, this is accomplished in the present inventionby providing a discontinuous pattern of polymeric material over theoutward facing side of the water-resistant water-vapour-permeable liner,so as to resist abrasion between the liner and the outer shell. However,the abrasion-resistant polymeric material does not have the disadvantageof becoming wetted by rain to any significant extent.

[0007] In particular, the present invention provides a garment whichcomprises:

[0008] an outer shell surrounding an inner liner;

[0009] the inner liner comprising a water-resistantwater-vapour-permeable material having a first side and a second side;

[0010] the first side facing the outer shell, and a discontinuouspattern of abrasion-resisting polymeric material being provided oversaid first side.

[0011] The invention also relates to the inner liner per se havingattachment means for attaching to an outer garment shell.

[0012] The outer garment shell may in principal be formed of any fabricor other material suitable for this purpose. It can be made of anysuitable weight of fabric, though lightweight fabrics are preferred toavoid making the overall garment too heavy. Generally, the fabric willbe one which retains water to a minimal extent and is fast drying. Itmay be treated with a conventional shower-proofing coating, includingwater repellant coatings or impregnations. The outer shell may surroundthe inner liner either completely or incompletely. For example, if theinner liner includes sleeves, the outer garment could be in the form ofa vest or waistcoat covering only the body part of the inner liner andleaving the sleeves free.

[0013] The outer shell may be fixed to the inner liner. However, aparticularly preferred embodiment, the outer shell is removable andinterchangeable. For example, a number of outer shells may be provided,each differing in terms of colour or fabric or each carrying differentlogos or wording. For example, a paramedic arriving at an emergencyscene might attach onto his inner liner an outer shell bearingparticular wording, such as “Supervisor”.

[0014] The outer shell is preferably removeably attached to the innerliner by conventional attachment means, such as zips, press studs,hooks, hook and eye fasteners e.g. Velcro (trademark). Typically, theouter shell is attached to the inner liner by a pair of zips extendingdown either side of the front opening of the garment. Thus, the outershell and the inner liner are usually only loosely attached to oneanother and there is a spacing between.

[0015] The inner liner comprises a water-resistantwater-vapour-permeable material. Suitable materials are disclosed inpatent specification GB2316341A. Thus, a preferred material comprises awoven or non-woven substrate, typically formed from expandedpolytetrafluoroethylene (ePTFE) coated on the first side facing theouter shell with a water-resistant water-vapour-permeable hydrophilicfilm of the type disclosed in patent specification U.S. Pat. No.4,194,041. The polymer is generally a hydrophilic polymer such as apolyurethane or polyester. The hydrophilic polymer may include a fillersuch as disclosed in patent specification GB9921103.9; nanometer sizedcarbon particles being particularly preferred in view of the improvedabrasion resistance that they impart.

[0016] The water-resistant water-vapour-permeable material mayalternatively comprise a microporous or hydrophilic material such as ahigh molecular weight microporous polyethylene, polypropylene,polyurethane, polyester or copolymers thereof.

[0017] The discontinuous pattern of abrasion-resisting material may bein the form of continuous lines or grids or in the form of unconnectedbodies of abrasion-resisting polymer, such as dots, chevrons, discretelines or other unconnected shapes. The dots may be any shape (inplan-view), such as squares, circles, ovals, rectangles, polygons etc.In order to minimise abrasion of the outer shell, shapes having sharpcorners are not preferred. Preferably, the dots are truncated pyramidal,truncated hemispherical, hemispherical or part-spherical inthree-dimensional shape. Generally, the polymeric material is partiallyraised from the surface of the hydrophilic material and the raisedprofiles are preferably smooth to avoid snagging of the inner lineragainst the outer shells

[0018] The pattern of dots may be a random pattern or an orderly patternaccording to a predetermined spatial geometry. Each dot preferably has amaximum diameter of 200 to 2000 microns, preferably 500 to 1000 microns.The dots may be spaced apart centre-to-centre by 250 to 3000 microns,particularly 800 to 1200 microns. Typically, the dots have a heightabove said first side of 50 to 500 microns, especially 100 to 400microns.

[0019] Typically, the abrasion-resisting polymeric material covers30-80%, preferably 40-75% and typically 50-70% of the first side of thematerial of the inner liner.

[0020] The abrasion resisting polymeric material may include aprepolymer which cures in situ, a UV light-curable polymer, a roomtemperature vulcanising polymer, or a thermoplastic polymer. Thepolymeric material may be applied to the substrate in liquid form from ahot melt, by solution coating or by emulsion coating. Suitableelastomeric polymers include polyesters, polyvinylchloride, polyamides,silicones, polyurethane, or polyurethane-polyester composites. Reactivepolyurethanes, such as blocked polymers, whose reactive groups unblockabove a certain temperature are especially useful. The cured polymerwill generally be resistant to conventional dry-cleaning solvents.Conventional application methods includes screen printings gravureprinting and spraying. The polymeric material may bewater-vapour-permeable or not, and the particular polymer will be chosensuch that the water-vapour-permeability of the inner liner is withinchosen limits.

[0021] A conventional textile lining may be laminated to the second sideor inner side of the liner material.

[0022] The water-vapour-permeability (MVTR) of the inner liner willgenerally be at least 1,000 or preferably at least 1500 and mostpreferably greater than 3,000 g/m²/day.

[0023] The water-resistance of the inner liner may be measured by theSuter water-resistance test. An acceptable practical indication ofwater-resistance is one in which there is no evidence of water beingforced through a sample by a pressure of 1.4 lbs per sq.inch (0.1kg/cm²) or more typically 2.0 lbs per sq.inch (0.14 kg/cm²).

[0024] Abrasion resistance may be measured employing a Martindaleabrasion machine of the type described in J.Text.Inst. 1942:33, T151.After a predetermined number of rubs, the material is removed and testedfor water-resistance until a leak is detected.

[0025] The term “garment” includes jackets, trousers, overcoats etc.

[0026] An embodiment of the present invention will now be described byway of example only in conjunction with the attached drawings, wherein;

[0027]FIG. 1 is a view of a garment i.e. a jacket, according to thepresent invention, and

[0028]FIG. 2 is a schematic cross-sectional view of the outer shell andinner liner construction.

[0029]FIG. 1 shows a jacket according to the present inventioncomprising an inner liner 2 and an outer shell 4 removably attachedthereto. Both the inner liner and outer shell are full garments i.e.they cover both the body and arms of the wearer.

[0030] The inner liner is attached to the outer shell by means ofhalf-zips 6,8 respectively down the front of the inner liner and outershell, which are removably connected by means of a zip clasp 9. Onecomplete zip is provided along each side of the front opening of thejacket.

[0031] The jacket is shown with the zip partially open to reveal aportion 10 of the inner liner, which is a first side of thewater-resistant water-vapour-permeable material, and on which isprovided the discontinuous pattern of abrasion-resisting polymeric dots.

[0032]FIG. 2 shows a detailed cross-section of the inner liner 2 and theouter shell 4.

[0033] Suitable fabrics for the outer shell 4 include filament, stapleor blends thereof of any suitable fibre including acrylics, polyesters,polypropylenes, nylons, aramids and melamines. They may be knitted,woven, non-wovens, impregnated fabrics or porous coated fabrics.Generally, the fabric has a moisture vapour permeability (MVTR) in therange 4000 to 19000g/m²/24 hr.

[0034] A preferred material for the outer shell is a 65% polyester, 35%cotton blend woven fabric, twill weave (weight 300 g/m²) treated with awater repellant finish (MVTR 19000 g/m²/24 hr).

[0035] Suitable test methods for measuring water resistance (Suter test)water-vapour-permeability (MVTR) and abrasion resistance are describedin patent specification GB2316341.

[0036] The inner liner 2 comprises an expanded polytetrafluoroethylenemembrane 20 of the type disclosed in patent specification U.S. Pat.3,953,566 having applied thereto a coating 22 comprising a hydrophilicpolymer as described in patent specification U.S. Pat. No. 4,194,041.

[0037] The ePTFE layer 20 and the hydrophilic polymer coating 22constitute the water-resistant water-vapour-permeable material of theinner liner. On a first side 24 thereof is applied a pattern ofpolymeric abrasion-resisting dots 26. The dots are applied in a rosettepattern. Each dot is in the shape of a truncated square pyramid ofdiameter approximately 780 microns and height 200 microns. Coverage istypically 60%. The composite inner liner laminate may be made by thecoating and lamination techniques described in GB2316341. Theabrasion-resisting polymer is a polyurethane polymer referred to asOLC-5T prepared according to Example 1 of patent specification U.S. Pat.No. 5,209,969. Silicone polymer could also be used.

[0038] Both the hydrophilic coating 22 and optionally the polymericabrasion-resisting dots comprise a filler consisting of nanometer sizecarbon particles.

[0039] Laminated to the inner face of the inner liner is a textilematerial which is aesthetically pleasing and may be any woven, knittedor non-woven material of any fibre type including nylons, aramids,melamines, acrylics. Typically, the textile lining 30 is a 100%polyester warp knitted, sueded material of a mass approximately 110g/m².

[0040] Generally, the inner liner has an overall moisture vapourpermeability in the region 3,000 g/m²/24 hr to 14,000 g/m²/24 hr.

[0041] The breathability of the garment as a whole (outer shell andinner liner) is greater than 2600 g/m²/24 hr.

[0042] The abrasion resistance of the inner liner was measured using aMartindale abrasion testing machine as described in patent specificationGB2316341. The abrasion resistance of the first side of the liner havingthe abrasion-resisting dot pattern was tested against 12 kPa abradentwool, and no leaks (1 psi for 3 mins) were detected after 105,000 rubs.Tested against 12 kPa 65% polyester/35% cotton blend fabric, no leaks (1psi for 3 mins) were detected after 20,000 rubs, and in fact the fabricabraded away first.

[0043] A further benefit of this construction is that seam sealing ofthe sewn seams of the inner liner is carried out over the first side ofthe inner liner i.e. over the polymeric dot pattern. Thus, the seamsealing tape is not visible on the inside of the garment but is hiddenby the presence of the outer shell.

1. A garment which comprises: an outer shell surrounding an inner liner;the inner liner comprising a water-resistant water-vapour-permeablematerial having a first side and a second side; the first side facingthe outer shell, and a discontinuous pattern of abrasion-resistingpolymeric material being provided over said first side.
 2. A garmentaccording to claim 1, which further comprises attachment means forremovably attaching the outer shell to the inner liner.
 3. A garmentaccording to any preceding claim wherein the water-resistantwater-vapour-permeable material comprises an expandedpolytetrafluoroethylene substrate coated with a hydrophilic coating. 4.A garment according to any preceding claim wherein the discontinuouspattern of abrasion-resisting polymeric material is in the form of apattern of dots.
 5. A garment according to claim 4, wherein each dotapproximates a truncated square pyramid.
 6. A garment according to claim5 wherein each dot has a maximum diameter of 500 to 1000 microns.
 7. Agarment according to claim 5 or 6 wherein each dot has a height of 100to 400 microns.
 8. A garment according to any of claims 4 to 7 whereinthe discontinuous pattern of abrasion-resisting material is in the formof continuous lines, grids or unconnected bodies of material.
 9. Agarment according to claim 5, 6 or 7 wherein the abrasion-resistingmaterial covers 50 to 70% of the first side of the inner liner material.10. A garment according to any preceding claim wherein theabrasion-resisting polymeric material is a polyurethane.
 11. An innerliner for a garment, which is formed of a water-resistantwater-vapour-permeable material having a first side and a second side; adiscontinuous pattern of abrasion-resisting polymeric material beingprovided over the first side; and which comprises attachment means forremovably attaching the inner liner to an outer garment shell such thatsaid first side having the pattern of abrasion-resisting polymericmaterial faces the outer garment shell.
 12. A liner according to claim11 wherein the discontinuous pattern of abrasion-resisting material isin the form of continuous lines, grids or unconnected bodies ofmaterial.